Disposable flashlight



June 20, 1967 w. H. GEY' 3,327,107

DI SPOSABLE FLASHLIGHT Filed Dec. 30, 1964 INVENTOR. WILLIAM H. GEY

BY J mm,wM%\-am ATTO R N EYS United States Patent 3,327,107 DHSPOFaABLE FLASHLIGHT William H. Gey, 126 Summer St., Boston, Mass. 02110 Filed Dec. 30, 1964, Ser. No. 422,357 2 Claims. (Cl. 24010.65)

ABSTRACT OF THE DISCLQSURE A small disposable flashlight contains a pair or dry cells enclosed by themselves in a heat-sealed plastic bag to protect the other parts of the flashlight in case of leakage of the cells. The push-button switch which projects through the wall of the casing is supported by a felt pad inserted between its inner end and an end of the battery cells.

This invention relates to improvements in small flashlights the parts of which are inexpensively made and permanently assembled so that when any part gives out, the entire flashlight is discarded. Flashlights of this type have been on the market for several years. It is an object of the present invention to build into flashlights of this kind features effective to lengthen the useful life of the flashlight.

The invention is exemplified in a flashlight in the form of a short cylinder having a diameter of 2 /2 inches and a length of /8 inch. This flashlight is hereinafter described, and is illustrated on the drawing, of which FIGURE 1 is a plan view, on an enlarged scale, of a flashlight embodying the invention, partially assembled;

FIGURE 2 is a perspective view of the batteries for the flashlight enclosed in a plastic bag;

FIGURE 3 is an exploded perspective view of one form of an end wall for the flashlight casing;

FIGURE 4 is a section on the line 44 of FIGURE 3; and

FIGURE 5 is an elevational view of a completed flashlight.

The flashlight shown in FIGUURE 1 comprises a short cylindrical wall member 11 of cardboard or the like on the edges of which thin brass rings 12 are secured by crimping or spinning. Each such ring is made with a narrow annulus surrounded by a bead 14 which receives an edge of the cylindrical wall. A switch 16 with a pushbutton 17 and the glass bulb 18 of an electric lamp 20 project through holes in the wall member 11. A spring clip 22 is secured within the casing to hold the lamp 20 in place. Two small dry-batteries 24, 26 are connected in an electrical circuit with each other and with the switch 16 and lamp 20 by wires 28, all the connections being soldered. This circuit is tested a number of times at intervals before insertion in the casing to determine whether any element in the circuit is defective.

In assembly the parts of a flashlight, one of the metal rings 12 is permanently secured to an edge of the cylindrical side wall and a clip 22 is fastened through the side wall. A disk 30 of cardboard is cut carefully to size so as to fit snugly within the head 14 of one of the rings 12 and to bear against the annulus. An assembly of batteries, lamp and switch is then inserted in the casing, but before that is done the batteries 24, 26 are encased in a small polyethylene bag 32 so that the wires 28 which connect the batteries to the switch and lamp protrude from the open end of the bag. The bag 32 is longer than the batteries, and the portions 33 of the sides of the bag that extend beyond the end of the batteries to which the wires 28 are connected are folded over one another against the adjacent end of the batteries to enclose them completely. The bulb 18 of the lamp is then thrust through the hole in the side wall of the casing through which the clip 22 is fastened. The switch 16 is thrust through the other hole in the casing from the inside, and the batteries encased in the bag 32, are inserted in the casing in line with the switch 16 with a felt pad 34 wedged in between the inner end of the switch and the adjacent end of the batteries. This keeps the folds of the end of the bag against one another and prevents the switch 16 from being pushed bodily into the casing when the button 17 is pressed.

When these parts have been installed in the casing, melted wax is poured in to a level about half way to the top of the cylindrical wall. For this purpose a wax or mixture of waxes having relatively high melting points F. or over) is used. Such waxes as ceresin, montan or carnauba can be employed with or without the admixture of a polymer of butylene. The molten wax soaks into the surface of the cardboard disk 30 and upon congealing anchors the disk securely in place. The heat of the molten wax seals the folds of the bag 32 together so that the batteries are completely sealed in the bag. An occasional battery may have a slight defect which results in the gradual escape of gas which, if there is no bag 32, is apt to react with adjacent wax, corrode the adjacent portion of the case, and shorten the useful life of the flashlight. This is prevented when the batteries are sealed in the bag 32 as described.

The bag 32 also serves another purpose when the flashlight is being assembled. It then acts as a temporary heat insulator when the molten wax is being poured into the casing so that the wax can be introduced at a lower temperature than is necessary when no bag is used. Before congealing, it is necessary for the wax to flow around and under the parts Within the casing.

After the first charge of wax has solidified, a second charge is poured in which nearly fills the casing. A second disk of cardboard is pressed into engagement with the upper ring 12 and the assembly is promptly inverted so that the molten wax will flow into contact with the second disk and anchor it in place.

The exterior surfaces of the cardboard cylindrical wall 11 and the two disks are preferably ornamented in a variety of ways. A modification can be had by substituting for one of the rings a wider ring 40 (FIGURE 3) with a circular central aperture 42, arcuate apertures 44, three such being shown in FIGURE 3 of the drawing, and three tongues 46 struck from the ring and projecting down. The ring 40 has a shallow channel in which a cardboard annulus 43 fits, covering the apertures 44. It also has an outer flange 50* and an inner flange 52. A disk 54 is fitted in the central aperture 4 2, the edges of this disk engaging under the innner flange 52. The tongues 46 are bent up against the under face of the disk 54 to hold it firmly in place in the aperture 42. The outer face of the disk 54 may be a mirror, may be ornamented as desired, or may carry advertising matter. The outer flange 50 is curled into engagement with an edge of the cylindrical casing wall for permanent attachment thereto.

The assembling of the flashlight as a whole proceeds as hereinbefore described, the ring 40 with its parts taking the place of the initial ring 12 and its disk 30. The first charge of molten wax reaches the cardboard ring 48 through the arcuate apertures 44 and anchors this ring in place. The wax also backs the central disk 54 and reinforces the tongues 46 in holding the rim of the disk 54 firmly against the inner flange 52.

I claim:

1. A pocket flashlight comprising a casing in the form of a short cylinder, two dry-battery cells disposed side by side in said casing, a heat-sealed polyethylene bag completely enclosing said cells by themselves, a push-button switch extending through the cylindrical wall of said casing near an end of said cells, a felt pad pressed between the inner end of said switch and the adjacent end of said cells, a lamp Within said casing having a bulb projecting through said wall, wires connecting in series said cells, said switch and said lamp, and a congealed waxy sub stance partially filling said casing.

2. A pocket flashlight as described in claim 1, said casing including one circular side Wall consisting of a sheet metal frame, a central circular disk mounted on said frame, and an annulus on said frame surrounding said disk.

References Cited UNITED STATES PATENTS 1,426,228 8/1922 Sloane 2406.45 1,539,427 5/1925 Rector 136-l32 1,921,171 8/1933 Smith 24010.65 2,529,972 11/1950 Scott ..l 240-6.45 2,879,381 3/1959 Coffey 240-10.65

FOREIGN PATENTS 704,710 2/1954 Great Britain.

NORTON ANSI-1BR, Primary Examiner. R. M. SHEER, Assistant Examiner. 

